Process of treating acid sludge



Patented May 8, 1934 UNiTED STATES PATENT OFFICE signor to Chemical Construction Corporation, Charlotte, N. C., a corporation'of Delaware N 0 Drawing. Application February 16, 1932, Serial No. 593,424

8 Claims.

This invention relates to a method of treating acid sludge obtained in the refining of petroleum, tar and other organic materials, and relates more particularly to an improved method for producing sulphurous acid gas and an acid-free fuel from acid sluldge; and has special reference to the provision of improvements in the "process of treating sludge set forth in my co-pending applications Serial No. 568,050, filed Oct. 10, 1931; Serial No. 571,775, filed Oct. 29, 1931; and Serial No. 574,244, filed Nov. 11, 1931.

In the process set forth in my said copending applications, acid sludge is subjected in a retort to the action of heat so that the organic matter of the sludge is made to react with the sulphuric acid or/and compounds thereof in the sludge to convert the same to S02 gas which is removed from the sphere of reaction. By the reaction, the sulphuric acid and compounds thereof in the sludge are reduced to an S02 gas substantially free of impurities which is produced in such a condition that it may be readily and efficiently converted in contact or catalytic apparatus to sulphuric anhydride and sulphuric acid. In addition to the obtaining of the S02 product, there results the production of a granular carbonaceous residue of an acid-free character having a high volatile content which forms a very desirable fuel product. I

As set forth in my said copending applications, particularly in my application Serial No. 571,775, the process of my invention is applicable to various kinds of sludges, including not only liquid and more viscous types of sludges, but also sludges of the heavier and more solid types and to sludges which are obtained by blending different kinds of sludges. I have discovered that the reaction that takes place in the retort, whatever the character of the sludge may be, is one between the sulphuric acid and certain of its compounds in the sludge and hydrocarbons in the sludge which furnish the hydrogen required for the reduction of the sulphuric acid. More specifically, I have empirically ascertained that if the sludge contains a disproportion of the reactable hydrocarbon and sulphuric acid components in the sludge, the reaction is retarded, resulting in a number of objections hereinafter set forth more in detail, and I have furthermore discovered that these objections may be cured and obviated and the reaction accelerated by adjusting the ratio between the reactable hydrocarbons and sulphuric acid or/and compounds thereof in the sludge.

The prime object of my present invention therefore comprises the provision of an improved method for treating acid sludge wherein the reactable components of the sludge which directly effect the reduction of the sulphuric acid and compounds thereof to S02 and theproduction of an acid-free fuel are adjusted or balanced.

To the accomplishment of this object and such other objects as may hereinafter appear, my invention consists in the processes and the steps of the processes hereinafter more particularly described and sought to be defined in the claims.

It will become manifest, as the description of the invention proceeds, that the principles of my present invention are applicable to various processes of treatingthe sludge wherein the reactable hydrocarbon and sulphuric acid components in the sludge are caused to react to effect the reduction of the sulphuric acid component and that such processes may include, for example, the heating of the sludge by either direct or indirect methods or treatments. The description of the present invention in connection with a preferred method of treating the sludge by subjecting the same to the action of hot combustion gases is therefore given herein by way of exemplification of the use and the many advantages of the pres- 30. ent improvementa'and not by way of limitation thereof.

In the process of treating acid sludge set forth in my aforesaid copending applications, a body of acid sludge is subjected in a retort to the action of hot combustion gases. In the practice of this process the reacting constituents of the sludge and the reacting conditions are so controlled as to generate S02 gas without producing such side reactions as result in the cracking or distilla- 90, tion of the heavy hydrocarbons, the destructive distillation of the carbonaceous residue, the distillation of sulphur, S03 or sulphuric acid, the generation of carbon monoxide or carbon dioxide gases, the ultimate formation or inclusion with the removed S02 gas of H25 gas, or the formation of dust, the reaction being, moreover, so carried out as to limit the formation to the minimum amount of the lighter hydrocarbons by distillation. Because of this, there results, as 0 aforementioned, the production of an S02 product substantially free of impurities and of a granular sludge residue in the form of a very desirable fuel of an acid-free character, having a high volatile content.

In the preferred practice of this process, the hot combustion gases are caused to flow over a sludge body in an elongated drum-shaped-retort, which sludge body is agitated during and by the rotation of said retort, the hot combustion gases, 110

granular fuel product.

' ly countercurrent directions.

produced in the retort are preferably withdrawn,

or expelled from the retort at one end of the same and at which end feed sludge is introduced into the sludge body in the retort, and the carbonaceous residue of the sludge is preferably withdrawn or removed from the retort at the opposite end of the same, at which opposite end the combustion gases are introduced into the retort. By suitably operating the retort and by suitably controlling the flow of the hot combustion gases and the feed sludge, the process may be practiced to controllably carry out the reactions .in the retort in the various sections or zones thereof.

The main reaction between the organic matter of the sludge and the sulphuric acid contentor compounds thereof in the sludge takes place in or about the middle reaction zone of the retort, although-the evolution of SOzbegins at the lower temperatures, the evolution taking place, however, with increasing power until the higher temperature range such as of the order of 380 to 420 F. is reached. The direct heating'of the sludge body while thelatter is in an agitated state accomplishes a uniform heat treatment and avoids :local overheating with its consequent dis-= advantages in producing side reactions. The S02 gases produced are of high concentration and are generated free of any sublimed sulphur and substantially wholly free of S03 gas, sulphuric acid mist or Hz'S gas; and this generated S02 gas contains but a small amount of volatile oil and a minimumamount of light hydrocarbons which maybe removed in the subsequent treatment of the gas by a simple form of condenser andscrubber. In the reaction zone at the lower temperature end of the retort evaporationof the water content of the sludge takes place (as well as distillation of the lighter hydrocarbons) to the point at which the sulphuric acid willreact with the organic matter in the sludge. There results also here a sludge body having a sulphuric acid of high concentration into which the weak feed sludge is charged. In the maction zone at the higher temperature end of the retort there takes place the final breaking up of the spongy carbonaceous residue of the sludge withfurther appliedheating, the remainder of the S02 mechanically held in the residue being here driven ofi and the residue being reduced to the The sludge mass during treatment in the various zones passes from a liquid stage to a plastic condition as it is progressively moved through the retort; and the fuel or carbonaceous residue does not quite lose this plastic condition, so that it is expelled from the retort in a cohering yet granular state. This character of the fueljproduct is in itself important because it avoids the formation of dust and the carrying over of dust with the produced'gases; and the transformation of the sludge mass from the liquid stage to the plastic condition is also an important desicleratum, since it is a factor not only in permitting the proper flow of the sludge mass through the retort, but in permitting the release of the reagents and the resulting products in and from the sludge, and furtherl more permits the reaction to be carried out with homogeneity and uniformity.

In this process of treating acid sludge (or similar carbonaceous residues) it has-been found, as

aforesaid, that the reaction between the sul-- phuric acid content .of the sludge and the carbon compounds therein takes place under the conditions of the process as a reaction between the sulphuric acid and compounds thereof in the sludge and some of the hydrocarbons which furnish the hydrogen required for he reduction of the sulphuric acid and compounds thereof. Due

to the proven fact that in my process substan- It is to be understood that the hydrocarbon formula; used in the above equations are used to represent types of hydrocarbons and not to represent the actual hydrocarbons which are the reactants these sludges. It has been further found that the reactable components of the sul-. phur bodies comprise the free sulphuric acid in the sludge as well as certain compounds thereof and particularly the sulfides and disulfides. The sulphcnic acids, however, are fairly stable high boiling compounds and probably do not liberate any 362 this process. More specifically, alkyl sulphuric acids and alkyl sulfides or polysulfides yield sulphur as $02 in this process, whereas sulphonic acids do not appear to yield appreciable amounts of sulphur as S02 in this process.

I have empirically ascertained from the character of these reactions thatwhere there exists an unbalance in or disproportion of the reactable hydrocarbon and sulphuric acid components in the sludge as practiced in this process, certain objections manifest themselves which I have fu1 found may be efiicaciously eliminated by balancing or adjusting the ratio or relative proportions of these reactable components. As the water is eliminated from the sludge in the retort, thereby increasing the concentration of the sulphuric acid, and as the sludge charge moves along in the kiln or retort with increasing concentraion of the acidand under the influence of increasing temperaturesfthe rate of the reaction tends to accelerate and as the charge further moves along-in the retort, the decreased mass of reacants tends to decrease the rate of action. In the zone or zones where the main reaction and liberation of the S02 takes place, it has been found that if a large amount or propor tion of oily hydrocarbons and a relatively small amount of sulphuric acid are present in the mix-' ture, the reaction is retarded and the carbonaceous residue, instead of being free flowing, be-= comes comparatively sticky or gummy as the re sult of the presence in the sludge of'the large arriount or proportion of unreacted hydrocarbon. If, conversely, a large excess of sulphuric acid component or reactable compounds thereof and a relatively small amount of hydrocarbon are present in the mixture, the reaction is also retarded, undesirable higher temperatures and longer periods of time being required to completely reduce the sulphuric acid content or component in the sludge. 7

By means of the principles of the present invention, these difficultiesmay be avoided by balthe re-.

ancing oradjusting the sludge .on the basis of a predetermined .ratio of reactable hydrocarbon and acid components so as to enable the process to proceed smoothly and regularly with the production of substantially the optimumamount and pure S02 gas at one end of he retort/and asubstantially dry acid-free and oil-ifreegranularfuel at the other end. Thisadjustment or balancing may be made for sludges either .too low or too high .inacidcontent. If the sludge under treat ment is of too low asulphuric acid content,.the adjustment of .theacid-hydrocarbon ratioismade by the addition of free sulphuric acid to the sludge, which sulphuric acid may be obtained from the drying towers :of the plant in azmanner such .as is disclosed in my aforesaid :application Serial No. 574,244, filed November 11, 1931, or by the addition of freesulphuricacid from any other source, or by the addition of anyacid-containing substances suchas ahighacid sludge from light oil'refining. If the sludge to be treated contains, on the other hand-too high a sulphuric acidcontent, the adjustment of the acid-hydrocarbon ratio is made by the addition of other hydrocar bons, preferably those of low commercial value or of any low acidecontaining sludge.

The exact adjustment of the ratio of the hydrocarbon and sulphuric acidcomponents in the sludge depends in a large measure upon thenature of the hydrocarbons present, which varies in different sludges. In general, it may be stated that the best results are obtainable when the reaotable sulphuric acid content in the sludge is between 30% and and more generally between 38% and of the sludge, within'which range the reacting hydrocarbon content seems to be sufficient to complete the reaction and at the same time reduce the oily material in the sludge to the point at which itdoes not affect the physical condition of the fuel residue. The clividing line betweenthe improper and the proper ratio within closer limits maybe determined empirically by laboratory or plant scale tests for each particular sludge.

and a relatively low reacting hydrocarbon content when heated (by external heat) ina laboratory decomposer for 4 hours at a temperature of 250 C. liberated only-68% of its S02, and this sample of sludge required 10 hours of continuous heating and an elevation of the temperature to 280 'C. to liberate 98% of its S02 on the basis of the sulphuric acid content. This sample of sludge requires an adjustment by the addition of other hydrocarbons. Another type of sludge when containing 38% of H280; and heated inthe decomposer to 255 C. for 3 hours showed a recovery of 108.5% S02, when containing 47% of H2S04 and heated similarly to 288 0. showed a recovery of 101.0% S02, and when containing 54% n s-o4 and heated similarly to 230 C. showed a recovery of 90.4% S02, all calculated on the basis of the free H2804 :content of the sludge. For this type of sludge the optimum ratio'to be selected is that yielding'38% H2804.

An example of a sludge adjustment under practical operating conditions in the apparatus and process of my said copending applications may now be given. A hard, sticky, semi-liquid sludge from the plant of the Standard Oil Company of New Jersey at Bayway containing approximately 19% free sulphuric acid, and separating on standing approximately 15% of free oil, when processed in a plant such as disclosed in my aforesaid copending application Serial No.

Thus a sample of one. type of sludge containing "78% sulphuric acid 568,050, produced asticky,.gummy, intermediate product in the retort whichseriously interfered with the normal flow :of the sludge material drying tower, this mixing producing an adjusted or balanced sludge containing approximately 30% of freesulphuric acid. When this adjusted or balanced sludge was fed .to the'retort andoperated under the conditions set forth in my'said copending applications, no difficulty wasexperi- .enced in the feeding .of .the adjusted :mixture through :the usual liquid feeding devices, the. 7

plant operated at full capacity, and nodifficrilty was experienced'in the intermediate stagesin the retort, the S02. gas being freely disengaged.

and liberated in-optimiun' quantity from the solid or semi-solidintermediate product, and a granular acid-free oil-freesolidfuel residue was obtained from the retort. 2

Where the sludge contains toohigh an amount or proportionof reactable sulphuric acid'or compounds, -it.is desirable, asaforesaid, to select a hydrocarbon having the oily "hydrocarbon constituent'aforementioned .or its equivalent. hydrocarbon products may be substituted for petroleum to secure the adjustment, and the character of such other hydrocarbon products may be readily'ascertained lay-experiment. The following experiments will be illustrative. Sullicient water was added to 96.42% I-I2S04 to make about 60 :Baum acid. The following mixture of sulphuric acid and-a coaltar was heated in a Other stream of air: 4.2340 grams H2804 96.42

65.32=2;6666 grams S02)+7 grams navalstores coal tar-F2 cc. H20. .This washeated to 210 C. in30.minutes-and.at210 to 260C. for 3 hours. From this 1.8223 grams S02 or 68.2% of the amount added was collected. A second mixture of this sulphuric acid and bituminous coal was heated in a stream of air: 2.3510 grams H2504 .96.42 65.32= 1.4806 grams S02) +1 cc. 'HzO-l- 2 grams bituminous coal. This was heated to a temperature of 170 to 210C. for 3 hours.

added, was recovered. Thus the coalrtar was found not to be an especially goodreducing agent, while the coal was found to be a good reducing agent for the sulphuric acid. In the first ex- From this 1.2821 grams S02, or 86.5% of the amount,

ample the coal tar aromatic hydrocarbons probably form sulphonicacids-which are stable at the treating temperatures, thus accounting for the adding additional acid, oil or sludge of different composition to an acid sludge from which is recovered not only the acid and carbonaceous contents of the original sludge, but also those of the added material. The balancing of the reactable constituents improves the physical condition of the sludge by reducing it to a uniform, free flowing liquid condition, thereby facilitating the handling and feeding of the sludge to, the sludge retort or kiln. 'By adjusting the ratio of the reactable constituents, I am enabled to remove more of the oily hydrocarbons, thereby resulting in the production of a dry, oil-free as well as acid-free carbonaceous residue, and I am further enabled to reduce to the minimum amount the distillation of the volatile oil, thereby facilitating the subsequent treatment of the reaction gases. By the use of the invention, the capacity of theretort or decomposer is increased when the same is used for handling heavy, low-acid sludges as the primary raw material. Furthermore, the tendency to the gumming-up or balling-up of the P reacting materials in the retort is effectively sludge by reducing it to a uniform free flowing" liquid condition is especially effective with a great many sludges which, while semi-liquid at high temperatures, are practically solid at normal temperatures and which sludges are obtained from highly developed cracking operations or from the treatment of certain heavy oils. Such sludges do not flow through pipe lines or valves, and such solid or plastic sludges constitute a substantial percentage of the sludge production of the United States which hitherto was considered as waste products and either put on the dump heap or in many cases burned as fuel or burned for disposal.

It will be further understood that while I have in the main described the practice of the principles of the present invention in connection with the improved method of treating sludge set forth in my copending applications, the process of my present invention may be widely varied to employ the underlying principles thereof and to effect any one or a number of the advantages flowing therefrom, all as I have attempted to define in the following claims.

I claim:

1. In the method of subjecting a hydrocarbon sulphuric acid sludge to heat treatment wherein the hydrocarbon acts to reduce the sulphuric acid or/and compounds thereof to S02, the steps of adjusting the ratio between the reactable hydrocarbons and sulphuric acid or/and its com- 7 pounds in the sludge by adding to the sludge of adjusting the ratio between the reactable hydrocarbons and sulphuric acid or/ and its compounds in the sludge by adding to the sludge either a hydrocarbon body if said ratio is low or a sulphuric acid body if said ratio is high, and of directly subjecting the adjusted sludge to the treatment of hot combustion gases.

3. In the method of subjecting a hydrocarbon sulphuric acid sludge to heat treatment wherein the hydrocarbon acts to reduce the sulphuric acid or/and compounds thereof ,to S02, the steps of adjusting the ratio between the reactable hydrocarbons and sulphuric acid or/and its com-. pounds in the sludge by adding either a hydrocarbon or a sulphuric acid'body to the sludge so that the sulphuric acid content is of the order of from to and of subjecting the adjusted sludge to said heat treatment.

4. In the method of subjecting a hydrocarbon sulphuric acid sludge to heat treatment wherein the hydrocarbon acts to reduce the sulphuric acid or/and compounds thereof to S02, the steps of adjusting the ratio between the reactable hy-, drocarbons and sulphuric acid or/and its come pounds in the. sludge by adding to the sludge either a hydrocarbon body if said ratio is low or a sulphuric acid body if said ratio is high, of subjecting the adjusted sludge to direct heat treatment to convert substantially all of the reactable sulphuric acid component to S02 and to produce a substantially acid-free carbonaceous granular residue. l v

5. In the method of subjecting a hydrocarbon sulphuric acid sludge to heat treatment wherein the hydrocarbon acts to reduce the sulphuric acid or/and compounds thereof to $02, the'steps of adjusting the ratio between the reactable hydrocarbon and'sulphuric acid components in the sludge by adding to the sludge either a hydrocarbon body if said ratio is low or a sulphuric acid body if said ratio is high, and of causing such components to react to reduce substantially all of the free sulphuric acid component to S02 and to produce asubstantially acid-free carbonaceous residue.

6. The methodof treating acid sludge which consists in adding either a hydrocarbon or sulphuric acid body to the sludge to adjust the ratio between the reactable hydrogen and sulphuric acid components in the sludge so that the sulphuric acid content of the sludge is from 30% to 60% thereof, and of causing the hydrogen and sulphuric acid components to react to reduce substantially all of the free sulphuric acid com ponent to S02.

"7. The method of treating an acid sludge low in acid content which consists in adding free sulphuric acid to the sludge to adjust the ratio between the reactable hydrocarbon and sulphuric acid components in the sludge, and of causing such components to react to reduce both the original and the added sulphuric acid component to S02 which is removed from the sphere of reaction.

8. The method of treating an acid sludge low in acid content which consists in adding free sulphuric acid to the sludge to adjust the ratio 1 r between the reactable hydrocarbon and sulphuric acid components in the sludge so that the sulphuric acid content is of the order of 30% to 60%, and of subjecting the adjusted sludge to the action of hot combustion gases at controlled temperatures to cause such components to react to reduce both the original and the added sulphuric acid component to S02 and to produce a substantially acid-free carbonaceous residue.

INGENUIN HECHENBLEIKNER. 

